Process and apparatus for making a leak proof cap and body assembly

ABSTRACT

A process and apparatus for forming a leak proof body and cap. The process including the steps of defining a mold cavity between a first mold part and a second mold part, injecting a molten material into the mold cavity thereby forming from the molten material a body and cap, and retracting the first mold part from the second mold part to separate the first mold part from the body and cap. Thereafter, engaging at least the body with a robotic arm and moving the body with the robotic arm into a capping device while the body and cap are at a temperature at which the material is not fully set. The body is then sealed by moving the cap into engagement with the body to form a leak proof seal.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus and process for making andsealing a cap and body assembly. More particularly, the presentinvention relates to a process wherein the cap and body assembly ismolded, moved to a capping device and then sealed by closing the capwhile the plastic of the body and cap has not fully set.

2. Description of Related Art

Leak proof plastic bodies of the type to which the present inventionrelates are generally injection-molded plastic bodies that have plasticcaps adapted to seal the body closed with a substantially hermetic seal.Such bodies are for example, the vials used to collect samples in thedairy industry or other containers having caps. The caps may or may notbe integrally connected to the bodies.

In the past such sealed bodies have been made by molding the bodies andcaps in a first process and then sterilizing and sealing the caps ontothe bodies in a separate process. In order to sterilize the interior ofthe bodies and to seal the caps onto the bodies, it has been known toheat and seal the caps and bodies under aseptic conditions.

U.S. Pat. No. 4,783,056 discloses a method for accomplishing sealing ofa cap onto a vial including a mold with several moving parts in whichthe vial may be molded and sealed in the same apparatus. This method offorming and sealing an aseptic vial eliminates the additional step ofsealing the vial under aseptic conditions because the sealing is donedirectly in the mold while the vial is still hot enough to maintain thenecessary pliability and sterility of the vial. However, this methodrequires the use of a mold which has moving parts for closing andsealing the cap on the vial.

OBJECTS AND SUMMARY

The present invention relates to a process for forming and sealing a capand a body with a leak proof seal where the body is transferred from amold where it is made to a capping device while the material of the bodyis still not fully set. The body is removed from the mold with a roboticarm and transferred to the capping device where the cap is placed on thebody before the material of the cap and body has fully set to establisha leak proof seal between the body and cap.

More specifically, the invention relates to a process for forming a leakproof body and cap including steps of defining a mold cavity between afirst mold part and a second mold part, injecting a molten material intothe mold cavity thereby forming from the molten material a body and cap,and retracting the first mold part from the second mold part to separatethe first mold part from the body and cap. Thereafter, engaging at leastthe body with a robotic arm and moving the body with the robotic arminto a capping device while the body and cap are at a temperature atwhich the material is not fully set. The body is then sealed by movingthe cap into engagement with the body to form a leak proof seal.

In accordance with another aspect of the invention, an apparatus forforming an leak proof body with a cap includes a mold, robotic arm and acapping device. The mold has a first mold part, a second mold part and amold cavity formed between the first and second mold parts. An injectingmeans for injects a molten material into the mold cavity to form a bodyand a cap. A retracting means retracts the first mold part from thesecond mold part to separate the first mold part from the body and cap.The robotic arm is configured to engage the body and cap, and move thebody and cap from the mold to the capping device. The capping deviceseals the cap on the body while the body and cap are at a temperature atwhich the material of the body and cap is not fully set.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be describe in greater detail with reference to theaccompanying drawings in which like elements bear like referencenumerals, and wherein:

FIG. 1 is a side view, in partial cross section of a preferredembodiment of the invention;

FIG. 2 is a side view, in partial cross section of the mold according toa preferred embodiment of the invention in an open position, with therobotic arm in position to receive the body and cap;

FIG. 3 is a side view, in a partial cross section of the preferredembodiment of the mold;

FIG. 4 is a cross-sectional view of a body and cap according to thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, the preferred embodiment of the presentinvention includes a mold 10 for forming a leak proof body and cap, arobot 12 for transporting the body, and a capping device 14 for sealingthe cap on the body.

The apparatus and process of the present invention can be used to make avariety of bodies including bottles, vials, spouts or any othercontainer requiring a leak proof seal. The invention will be describedin the drawings and description with respect to a vial. However, itshould be understood that the process and apparatus of the inventionapplies equally to any body having a leak proof plastic seal.

The vial 16, as best shown in FIGS. 3 and 4, is perfectly cylindrical inshape with an integrally formed bottom. A cap 18 is provided which isadapted to seal the vial closed with a substantially hermetic seal. Thecap 18 is preferably integrally connected to the vial 16 with a smallflange 20. The vial 16 and cap 18 are preferably injection molded in themold 10 from a thermoplastic material.

The cap 18 includes a circular, flat center portion 22 having a rim 24extending perpendicularly from the outer edge thereof. The rim 24 isintended to fit over the upper edge 26 of the outer wall 28 of the vial16 in a sealing manner. A ridge 30 may be formed on the inside of thecap rim 24 to enhance the seal of the cap 18 to the vial 16.

As shown in FIG. 4, the vial 16 has an annular ridge 66 extending aroundthe periphery of the vial 14. The ridge 66 and the smooth transitionsurface at the upper edge or rim 26 of the vial 16 form an annularregion for interlocking with the cap 18.

With specific reference to FIGS. 2 and 3, the mold 10 primarily includesa first mold part comprising an end plate or end mold part 32, anintermediate plate 34, and a stripper plate or interior mold part 36,and a second mold part comprising a central portion 38. The second moldpart is arranged on a mold frame 40.

The intermediate plate 34 is connected to the end plate 32 by means ofbolts or other suitable fastening means (not shown). When the mold 10 isin an original configuration, the stripper plate 36 is arranged betweenthe intermediate plate 34 on the side and the frame 40 and the centralportion 38, on the other side.

A press means (not shown) is provided to both hold all three plates 32,34, 36 against the frame 40 with a predetermined pressure during theinjection process and to retract the end and intermediate plates 32, 34away from the frame 40 after the vial 16 has been injected. A bolt 42,threadedly engaged with the stripper plate 36 is arranged with its head44 located within a chamber 46 in the end and intermediate plates 32,34. A shoulder 48 of the chamber 46 is designed to engage the bolt head44 after the end and intermediate plates 32, 34 have travelled about oneinch away from the stripper plate 36. The contacting of the bolt head 44with the shoulder 48 prevents any further separation of the stripperplate 36 from the end and intermediate plates 32, 34.

A cavity 50 is formed within the plates 32, 34, 36, and a spring 52,such as a red die spring, is arranged within the cavity 50 undercompression when the mold 10 is closed. The effect of the spring 52 isto apply a repulsive force between the stripper plate 36 and the end andintermediate plates 32, 34.

Accordingly, when the press means is pulling the end and intermediateplates 32, 34 away from the frame 40, during the first inch of travel ofthe plates 32, 34, the spring 52 will hold the stripper plate 36 againstthe frame 40 with a reducing force. After about one inch of travel, thebolt head 44 will contact the chamber shoulder 48, and the stripperplate 36 will then be drawn by the press means away from the frame 40.

If the separation distance between the stripper plate 36 and theintermediate plate 34 is substantially greater than one inch,undesirable stresses are created in the spring 52. These stresses maylead to premature failure of the spring 52.

A rod 54 is fastened within the intermediate plate 34, and extendsthrough an opening 56 in the stripper plate 36 and into a bore 58located in the frame 40 of the mold 10. The rod 54 maintains the plates32, 34, 36 in alignment with each other and with the frame 40 of themold 10 during opening and closing of the mold. Preferably, once suchrod arrangement is provided in each corner of the mold 10.

A first core 60 is mounted within the intermediate plate 34 so as toproject through a first opening 62 in the stripper plate 36 and into arecess within the central portion 41 of the mold 10. The first core 60provides a mold surface for forming the interior wall 64 of the vial 16during the molding process. The first core 60 and the central portion 38of the mold together form a mold cavity in which the vial 16 is formed.

A second core 72 is mounted within the intermediate plate 34 so as toproject through a second opening 74 in the stripper plate 36. A base 76of the second core 72 comprises the mold surface that forms the interiorsurface 78 of the vial cap 18. A recess 80 is provided in the base 76 ofthe second core 72 for forming an annular seal 82 projecting from theinterior surface 78 of the vial cap 18. The first and second cores 60,72 are described in more detail in U.S. Pat. No. 4,783,056 which isincorporated herein by reference.

As shown in FIG. 4, a seal 82 of the cap 18 is provided with an inneredge 84 and an outer edge 86 that are substantially perpendicular to theinterior surface 78 of the vial cap 18. An end surface 88 of the seal 82interconnects the inner edge 84 with the outer edge 86, and intersectsthe edges with an angle of about 45°.

The seal 82, and the cap rim 90 combine to form an annular region forinterlocking with the interlocking annular region on the vial 16. Theannular seal 82 is adapted to at least partially fit within the upperedge 26 of the vial wall 28. The end surface 88 is angled so as to guidethe upper edge 26 of the vial wall into the annular gap 94 formedbetween the seal 82 and the outer cap rim 90.

The annular rim 26 of the vial 16 is designed to fit within the gap 94.When the vial is closed before the material of the vial is fully set aleak proof seal results between various engaging portions of the cap 18and the vial 16.

With reference now to FIG. 3, the central portion 38 of the mold 10 fitswithin a recess in the frame 40. The central portion 38 has asubstantially cylindrical recess, the wall of which provides a surfacefor forming the outer wall of the vial 16. Annular water channels 96extend around an outer periphery thereof through which channels 96 wateris circulated to facilitate cooling during the molding process. O-rings98 are provided adjacent the channels 96 to maintain a seal around them.

The end plate 38 has a water channel 100 extending therethrough. Thewater channel 100 interconnects with water channels 102 extendinglongitudinally through the first and second cores 60, 72. O-rings 104are positioned adjacent the interconnection of the water channels 102 ofthe cores 60, 72 and the water channel 100 of the end plate 32 in orderto enhance the seal therebetween. The water channels 96, 100, 102facilitate cooling of the mold during the molding process.

Located within the frame 40 of the mold 10 adjacent the base of thefirst core 60 is a sprue gate 106 through which molten plastic isinjected into the mold 10. The diameter of the sprue gate 106 ispreferably about 0.060″, and is chosen to allow the plastic to beinjected into the mold 10 at as rapid a rate as reasonably possible. Theair vents 108 facilitate the rapid injection of plastic by allowing airpresent in the mold 10 to escape while the plastic is being injected.

Also located within the frame of the mold 10 adjacent the base of thefirst core is a poppet 110 which is used to eject the vial 16 from themold 10 when the vial is sufficiently cooled to retain its shape but isstill not fully set. The poppet 110 may be either an air poppet, asshown, or a mechanical pusher. The poppet 110 is preferably positionedat an angle with respect to the vial 16 so that the vial is ejectedwithout marking the surface of the vial.

In operation of the mold 10, the end, intermediate and stripper plates32, 34, 36 are held against the frame of the mold 10 with about 15fifteen tons of pressure by a press means (not shown). Molten plastic isthen injected through the sprue gate 106 with about fifteen tons ofpressure so as to form the vial 16 and cap 18.

In an illustrative, preferred embodiment the injected vials are allowedto cool for about six seconds while the temperature thereof drops fromabout 550° F. to about 100°-120° F. The specific temperature to whichthe vial 16 is reduced may vary with the size and type of vial butshould be cool enough so that the plastic will retain its shape, and hotenough so that the plastic is not fully set. Water is circulated throughthe water channels 96, 100, 102 of the mold 10 in order to acceleratethe cooling of the vial 16 and the cap 18.

When the vial 16 and the cap 18 are sufficiently cooled, the end plate32 and the intermediate plate 34 are withdrawn from the frame 40 of themold 10. As described above, as the end and intermediate plates 32, 34initially move away from the frame 40, the spring 52 acts between thestripper plate 36 and the end plate 32 to hold the stripper plate 36against the frame 40. After the end and intermediate plates 32, 34 haveseparated from the stripper plate 36 by about one inch, the head 44 ofthe bolt 42 engages with the shoulder 48 of the chamber 46 within theend and intermediate plates 32, 34 and pulls the stripper plate 36 awayfrom the frame 40. The rods 54 are guided within their respectiveopenings 56 and bores 58 to maintain the three plates 32, 34, 36 inalignment with the frame 40 during the separation of the plates 32, 34,36 from the frame 40. The first and second cores 60, 72 being attachedto the intermediate plate 34, move away from the frame 40 together withthe plates 32, 34, 36.

The plates 32, 34, 36 and the frame are preferably mounted on parallelrails (not shown) so that they remain in an aligned relationship evenwhen the mold is opened. As seen in FIG. 2, the plates are moved awayfrom the frame a sufficient distance to a allow a portion of a roboticarm 112 to move down between the plates 32, 34, 36 and the frame 40 andremove the vial 16 from the mold 10.

Although the invention has been described with respect to a particularmold it should be recognized that other types of molds could be used toform the bodies and caps according to the invention.

As shown in FIG. 1, a robot 12 is provided having at least three degreesof freedom for moving the vial 16 from the mold 10 to the capping device14. The robot 12 includes the robotic arm 112 having a plate 114attached to a lower end. The robotic arm 112, which is shown in a raisedposition in FIG. 1, is movable vertically on a vertically oriented track116. The vertical motion of the robotic arm 112 allows the plate 114 tobe lowered down to a position in which the plate 114 is directly infront of the vial 16 positioned in the central portion 41 of the mold.Alternatively, the robot 12 can be arranged to remove the vial from theside of mold 10.

The robot 12 is also provided with a horizontally oriented track 118 onwhich the robot 12 moves from a position A above the mold 10 to aposition B above the capping device 14. The robotic arm 112 is providedwith a pivot 120 having an axis parallel to the horizontally orientedtrack 118 so that the plate 114 may pivot at least 90°. An example of arobotic device which would be appropriate for performing the function ofmoving the vials quickly from the mold 10 to the capping device 14 isthe W312 robot which is manufactured by Wittmann Robot & AutomationSystems, Inc.

As shown in FIG. 2, the plate 114 on the end of the robotic arm 112includes first and second suction cups 122, 124 mounted thereon. Thefirst suction cup 122 is sized and configured to fit within and engagethe cap 18 of the vial 16. The sides 126 of the first suction cup 122are preferably angled outward from the center of the suction cap in adirection away from the plate 114. The second suction cup 124 isconfigured to fit within and engage the upper rim 26 of the vial 16 andis spaced from the first suction cup 122 an appropriate distance. Thesides 128 of the second suction cup 124 are preferably angled inwardtoward the center of the suction cup in a direction away from the plate114 so that the second suction cup 124 will fit easily within the upperrim 26 of the vial 16 without damaging the vial. The suction cups 122,124 are preferably made of an extremely flexible plastic material whichis more flexible than the material of the vial 16 and cap 18 so that thesuction cups 122, 124 will not deform the vial and cap.

A vacuum source (not shown) is provided and a vacuum line 130 attachesthe vacuum source to each of the suction cups 122, 124. It should berecognized that although the preferred embodiment utilizes two suctioncups other embodiments using a single function cup in either of the vial16 or cap 18 are also be within the scope of the invention.

Although suction cups have been described as the preferred means forengaging the vial, other means for engaging can be used as long as theydo not puncture or otherwise damage the vial. One such engaging means isa grasping claw which grasps the upper edge 26 of the vial 16.

In operation, the robotic arm 112 slides down along the vertical track116 until the plate 114 is positioned so that the suction cups 122, 124are aligned with the vial 16 and cap 18. The poppet 110 of the mold 10is then activated to pop the vial 16 from the mold 10. The vial 16 isstopped from ejecting all the way from the mold 10 by the plate 114. Thesuction source is activated either immediately after or simultaneouslywith the activation of the poppet 110. The plate 114 then is moved awayfrom the mold frame 40 to remove the vial 16 completely from the centralportion 41 of the mold 10. This motion of the plate away from thecentral portion 41 to remove the vial completely from the mold may beprovided by rotation of the robotic arm 112 about the pivot 120 in whichcase the vial would be slightly flexed. Alternatively, the vial may beremoved from the central portion 41 of the mold 10 by providing arobotic device with an additional degree of motion which allows the vial16 to be removed along the axis of the vial 16.

Once the vial 16 is completely removed from the central portion 41 ofthe mold frame 40 the plate 114 with the attached vial 16 is removedvertically from the mold 10. The robot 12 then travels along thehorizontal track 118 to transport the vial 16 to the capping device 14.The vial 16 is then rotated into a vertical position by rotation of theplate 114 about the pivot 120. The vertically positioned vial 16 is thenlowered into a holder 132 of the capping device 14 by moving the roboticarm 112 along the vertical track 116. The orientation of the mold 10,the robot 12 and the capping device 14, as shown in FIG. 1 is forconvenience. However, other orientations may be used without departingfrom the scope of the invention.

In order to provide a seal between the cap and the vial which is leakproof the cap 18 must be mated with the vial rim 26 when the plastic isnot yet set. The sealing of the cap to the vial while the plastic is notyet set allows the cap and vial to conform to each other and to form therequired leak proof seal. However, the cap cannot be placed on the vialuntil the plastic has cooled enough so that the cap and vial will notmelt into one another. Sealing of the cap too soon will cause the cap tobe permanently fixed and unremovable.

It is necessary to remove the vial from the mold and move it to thecapping device within a particular window of time where the plastic isrigid enough to be moved without deforming the vial 16 and the plasticis not yet fully set. This window of time will vary for difficultmaterials and different sizes and shapes of vials. The amount of timebefore some plastics set may be as long as 2 minutes, however, it ispreferred that the vial is sealed within 1 minute of being formed. Mostpreferably the vial is formed, moved and closed within a 45 secondwindow.

The capping device 14, as shown in FIG. 1, is used to close the cap 18onto the vial 16 within the window of time in which the plastic of thevial 16 and cap 18 is rigid enough to withstand moving but is not yetfully set. The vial holder 132 is provided with two or more arms 134which are preferably operated by pneumatic cylinders (not shown).However, it should be recognized that a mechanical mechanism may couldalso be used to open and close the arms 134.

A rotary flipper 136 is positioned adjacent the vial holder 132 forclosing the cap 18 of the vial 16. The flipper 136 is shown in FIG. 1 ina position half way between an open position and a closed portion. Theflipper 136 is provided with an actuator 138 which may be either apneumatic actuator or a motor driven actuator. According to a preferredembodiment of the invention, one or more controlled air jets (not shown)are provided which act on at least one surface of an arm of the flipper.

A conveyor 140 for transporting cartons 142 is positioned below the vialholder 132 so that the sealed vials may be dropped directly into thecartons 142. According to a preferred embodiment of the invention, theflipper 136 is provided with a sensor which senses when the flipper 136has sealed the cap 18 on the vial 16. The arms 134 of the vial holder132 move apart, in response to a signal from the sensor, to drop thesealed vial 16 into the awaiting carton 142.

While the invention has been described in detail with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modification can be made, and equivalentsemployed, without departing from the spirit and scope of the invention.

We claim:
 1. A process for forming a leak-proof body and cap comprisingthe steps of: defining a mold cavity between a first mold part and asecond mold part; injecting a molten plastic material into at least onemold cavity in the second mold part thereby forming from the moltenmaterial a body and cap; retracting the first mold part from the secondmold part to separate the first mold part from the body and cap;engaging at least one of the body and cap before the material is fullyset with engagement means on a robotic arm ; inserting a robotic armbetween the first mold part and the body and cap; ejecting the bodypartially from the second mold part before the body and cap are fullyset; removing the body and cap completely from the mold by the roboticarm by engaging at least one of the body and cap; moving the body andcap with the robotic arm into a capping device while the body and capare at a temperature at which the material is not fully set; and sealingthe body in the capping device before the material is fully set bymoving the cap into engagement with the body to form a leak-proof sealbefore the material is fully set.
 2. The process claim 1, wherein theengaging step comprises: inserting a receiving means between the firstmold part and the body with the robotic arm; ejecting the body partiallyfrom the mold until the body and cap engage the receiving means;removing the body completely from the second mold part with the roboticarm.
 3. The process of claim 2 1, wherein the ejecting step comprisesactivating a poppet in the mold.
 4. The process of claim 2 1, whereinthe receiving meansrobotic arm inserted between the first mold part andthe body isincludes a plate having at least one suction cup thereon. 5.The process of claim 4, wherein the ejecting removing step comprisesactivating a suction source connected to the at least one suction cup.6. The process of claim 1, further comprising a step, prior to theretracting step, of cooling the vial to a temperature at which thematerial will maintain its shape but is not fully set.
 7. The process ofclaim 1, wherein the sealing step comprises pivoting part to move thecap with respect to the body so as to guide the cap into engagement withthe body to form a leak proof seal.
 8. The process of claim 7, furthercomprising the steps of: providing a signal which indicates when thepivoting part has sealed the cap on the body; and dropping the sealedbody from the capping device in response to the signal.
 9. The processof claim 1, wherein the temperature of the vial body during thegrasping, moving and sealing steps not fully set condition is about100-120° F.
 10. The method of claim 1, further comprising the step orapplying suction through the engagement means to engage said one of thebody and cap to the robotic arm.
 11. The method of claim 1 4, whereinthe engagement meansmaterial forming the at least one suction cup issofter than the material forming the body and cap.
 12. The process ofclaim 1, wherein the step of engaging removing is performed withoutdamaging sealing surfaces on the body and cap.
 13. The process of claim1, wherein the body and cap are formed with a connecting hinge.
 14. Theprocess of claim 1, wherein both the body and the cap are engaged by theengaging means.
 15. A process for forming an aseptic, leak-proof vialwith a cap comprising the steps of: defining a mold cavity between anend mold part and an interior mold part on one side and a second moldpart on the other side, wherein said interior mold part and said secondmold part are in direct contact with each other; injecting a moltenmaterial into the mold cavity thereby forming from the molten material avial and a cap, said vial having an annular region at the top edgethereof for interlocking with an annular region at the interiorperiphery of the cap; retracting the end mold part from the interiormold part to separate the end mold part from the vial and cap whileapplying a biasing force against the interior mold part so as to biasthe interior mold part against the rest of the mold to retain the vialand cap within the second mold part; limiting the distance that the endmold part is separated from the interior mold part; retracting theinterior mold part from the second mold part when the end mold part hasbeen retracted a predetermined distance from the interior mold part;ejecting the vial and the cap at least partially from the mold beforethe material is fully set; engaging at least one of the vial and capwith engagement means on a robotic arm; moving the vial with the roboticarm into a vial holder having a pivoting part while the vial is at atemperature at which the interior of the vial is in an aseptic conditionand the material has not fully set; pivoting the pivoting part to movethe cap with respect to the vial so as to guide the interlocking annularregion of the cap onto the corresponding interlocking annular region ofthe vial so as to seal the cap on the vial before the material is fullyset and while the interior of the vial is in an aseptic condition. 16.The process of claim 15, further comprising the steps of: providing asignal which indicates when the pivoting part has sealed the cap on thevial; and dropping the sealed vial from the vial holder in response tothe signal.
 17. The process of claim 15, further including a step ofventing from the mold cavity gases that are released during theinjecting step.
 18. The process of claim 15, further comprising a stepof cooling the vial and cap to about 100-200° F. before retracting theend mold part.
 19. The process of claim 15, wherein the temperature ofthe vial during the grasping, moving and sealing steps is cool enough sothat the material is not deformed and is hot enough so that the materialis not fully set.
 20. The process of claim 19, wherein the temperatureof the vial during the grasping, moving and sealing steps is about100-120° F.
 21. A process for forming a leak-proof body and capcomprising the steps of: defining a mold cavity between a first moldpart and a second mold part; injecting a molten plastic material into atleast one the mold cavity in the second mold part thereby forming fromthe molten material a body and cap; inserting a receiving means roboticarm between the first mold part and the body with a robotic arm thesecond mold part; ejecting the body partially from the mold cavitybefore the body and cap are fully set until the body and cap engage thereceiving means ; removing the body completely from the second mold partcavity with the robotic arm by engaging at least one of the body andcap; moving the body and cap with the robotic arm into a capping devicewhile the body and cap are at a temperature at which the material is notfully set; and sealing the body before the material is fully set bymoving the cap into engagement with the body to form a leak-proof seal.22. The process of claim 21, wherein the step of engaging removing isperformed without damaging sealing surfaces on the body and cap.
 23. Theprocess of claim 21, wherein the ejecting step comprises activating apoppet in the mold.
 24. The process of claim 21, wherein the receivingmeans inserted between the first mold part and the body is a platehaving at least one suction cup thereon.
 25. A process for forming aleak-proof body and cap comprising the steps of: defining a mold cavitybetween a first mold part and a second mold part; injecting a moltenplastic material into at least one mold cavity in the second mold partthereby forming from the molten material a body and cap; receiving thefirst mold part from the second mold part to separate the first moldpart from the body and cap; removing at least partially the body and capfrom the mold cavity before the material is fully set; engaging at leastone of the body and cap before the body and cap are fully set withengagement means on a robotic arm; moving the body and cap with therobotic arm into a capping device while the body and cap are at atemperature at which the material is not fully set; sealing the bodybefore the material is fully set by moving the cap into engagement withthe body to form a leak-proof seal.
 26. An apparatus for forming aleak-proof body with a cap comprising: a mold having a first mold part,a second mold part and a mold cavity formed between the first and secondmold parts; an injection means for injectingdevice adapted to a inject amolten material into the mold cavity to form a body and a cap; aretracting means for retrievingdevice adapted to retract the first moldpart from the second mold part to separate the first mold part from thebody and cap; an ejection device adapted to eject the body and cappartially from the second mold part before the body and cap are fullyset; a robotic arm having engagement means configured to insert therobotic arm between the first mold part and the body and to engage atleast one of the body and the cap before the body and the cap are fullyset and to move the body and cap from the mold to a capping devicebefore the material is fully set; and a capping device for sealing thecap on the body while the body and cap are at a temperature at which thematerial of the body and cap is not fully set.
 27. The apparatus ofclaim 26, further comprising: a plate mounted on the robotic arm forengaging the body and cap; and a grasping meansa suction cup mounted onthe plate for grasping either the body or the cap.
 28. The apparatus ofclaim 26, wherein the capping device further comprises a pair of movablearms for holding the body and a flipper for moving the cap intoengagement with the body.
 29. The apparatus of claim 26, furthercomprising suction means suction cup for engaging said one of the bodyand cap.
 30. The apparatus of claim 26 27, wherein the engagementmeansmaterial forming the suction cup is softer than the not fully setmaterial.
 31. A process for forming a leak-proof body and cap comprisingthe steps of: defining a mold cavity between first and second moldparts; injecting a molten plastic material into the mold cavity to forma body and cap; separating the first and second mold parts; inserting arobotic arm between the first and second mold parts; ejecting the bodyand cap partially from the mold cavity before the body and cap are fullyset; removing the body and cap completely from the mold cavity by therobotic arm by engaging at least one of the body and cap; moving thebody and cap with the robotic arm into a capping device before thematerial is fully set; moving the cap into engagement with the body inthe capping device before the moving material is fully set to form aleak-proof seal.
 32. The process of claim 31, wherein the temperature ofthe body in the not fully set condition is about 100°-120° F.
 33. Theprocess of claim 31, wherein the temperature of the body and cap in thenot fully set condition is about 100°-120° F.
 34. The process of claim31, wherein the body and cap are formed with a connecting hinge.
 35. Theprocess of claim 31, wherein the removing step includes the further stepof applying suction through a suction cup connected to the robotic armto engage at least one of said body and cap.